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How to Replace timing chain on Audi A4 (B6) 1.9 TDI 2001

Audi A4 (B6) 1.9 TDI 2001 cambelt change instructions and replacement inteval. Full guide!

Special tools

  • Camshaft locking tool – No.3359.
  • Crankshaft sprocket locking tool – No.T10050.
  • Support guides – No.3369.
  • Tensioner locking tool – No.T10008.
  • Two-pin wrench – No.3387.
  • Viscous fan pulley holding tool – No.3212. 4 mm drill bit.

Special precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT turn engine via camshaft or other sprockets.
  • Observe all tightening torques.

Repair times – hrs

Camshaft drive belt/chain – R & I 2,60
Camshaft drive belt/chain, AT – R & I 2,60

Valve timing procedures

How to Replace timing belt on Audi A4 (B6) 1.9 TDI 2001
How to Replace timing belt on Audi A4 (B6) 1.9 TDI 2001

Removal

  1. Move radiator support panel into service position:
    • Remove front bumper.
    • Remove air intake pipe between front panel and air filter.
    • Remove front panel bolts [1] & [2] .
    • Install support guides No.3369 in front panel [3] .
    • Slide front panel forward.
  2. Raise and support front of vehicle.
  3. Disconnect exhaust pipe for auxiliary heater from engine undershield (if fitted).
  4. Remove:
    • Engine top cover.
    • Engine undershield.
    • Auxiliary drive belt.
    • Cooling fan assembly. Use tool No.3212.
    • Auxiliary drive belt tensioner.
    • Bolts for coolant pipe brackets (if required).
    • Timing belt upper cover [4] .
  5. Move turbocharger (TC) wastegate regulating valve.
  6. Remove:
    • Crankshaft pulley bolts [5] .
    • Crankshaft pulley [6] .
    • Timing belt centre cover [7] .
    • Timing belt lower cover [8] .
  7. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing mark aligned with notch on camshaft sprocket hub [9] .
    NOTE: Notch located behind camshaft sprocket teeth.
  8. Lock crankshaft sprocket [10] . Use tool No.T10050.
  9. Ensure timing marks aligned [11] .
  10. Lock camshaft [12] . Use tool No.3359.
  11. Fully insert Allen key into tensioner pulley [13] .
  12. Turn tensioner pulley slowly anti-clockwise until locking tool can be inserted [14] . Tool No.T10008.
  13. Slacken tensioner nut [15] .
  14. Remove:
    • Automatic tensioner unit [16] .
    • Timing belt.

Installation

  1. Ensure camshaft locked with tool [12] . Tool No.3359.
  2. Ensure crankshaft sprocket locking tool located correctly [10] . Tool No.T10050.
  3. Ensure timing marks aligned [11] .
  4. Ensure automatic tensioner unit locked with tool [14] . Tool No.T10008.
  5. Slacken camshaft sprocket bolts [17] .
  6. Turn camshaft sprocket fully clockwise in slotted holes. Tighten bolts finger tight [17] .
  7. Turn tensioner pulley slowly clockwise [18] until lug [19] just reaches stop [20] . Use tool No.3387 [21] .
  8. Fit timing belt in following order:
    • Camshaft sprocket.
    • Tensioner pulley.
    • Crankshaft sprocket.
    • Water pump sprocket.
  9. Install automatic tensioner unit [16] .
  10. Turn tensioner pulley slowly anti-clockwise [22] (lug [19] moves towards stop [23] ). Use tool No.3387 [21] .
  11. Remove locking tool without force [14] .
    NOTE: Ensure two-pin wrench remains in position.
  12. Allow tensioner pulley to turn back slowly [21] (lug [19] moves towards stop [20] ) until dimension [24] is 4±1 mm. Use drill bit.
    NOTE: Engine must be COLD.
  13. Tighten tensioner nut [15] . Tightening torque: 20 Nm + 45°.
  14. Tighten camshaft sprocket bolts [17] . Tightening torque: 25 Nm.
  15. Remove:
    • Camshaft locking tool [12] .
    • Crankshaft sprocket locking tool [10] .
    • Drill bit.
  16. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
  17. Ensure dimension [24] is 4±1 mm. Use drill bit.
  18. If not: Slacken tensioner nut [15] . Turn tensioner pulley until dimension as specified [24] . Tighten tensioner nut [15] . Tightening torque: 20 Nm + 45°.
  19. Lock crankshaft sprocket [10] . Use tool No.T10050.
  20. Ensure timing marks aligned [11] .
  21. Ensure camshaft locking tool can be inserted easily [12] . Tool No.3359.
  22. If not:
    • Slacken camshaft sprocket bolts [17] .
    • Turn sprocket hub until locking tool can be inserted [12] .
    • Tighten bolts [17] . Tightening torque: 25 Nm.
    • Remove locking tools [10] & [12] .
    • Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
    • Ensure locking tools can be fitted correctly [10] & [12] .
  23. Remove:
    • Camshaft locking tool [12] .
    • Crankshaft locking tool [10] .
    • Drill bit.
  24. Install components in reverse order of removal.
  25. Tighten crankshaft pulley bolts [5] . Tightening torque: 10 Nm + 90°. Use new bolts.
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